Pressure distributing aligned arrays of cushioning void cells

ABSTRACT

Implementations described and claimed herein include a cellular cushioning system comprising a first matrix of void cells, and a second matrix of void cells opposing the first matrix of void cells, wherein one or more peaks of each void cell in the second matrix is attached to one or more peaks of each void cell in the first matrix, and wherein the void cells of the first matrix have a higher cell resolution than the void cells of the second matrix. In another implementation, a method of manufacturing a cushioning system includes molding a first matrix of void cells, molding a second matrix of void cells, the void cells of the first matrix having a higher cell resolution than the void cells in the second matrix, and attaching peak surfaces of the void cells of the first matrix and peak surfaces of the void cells of the second matrix together.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of pending U.S. patentapplication Ser. No. 15/206,592, entitled “Pressure Distributing AlignedArrays of Cushioning Void Cells,” filed on Jul. 11, 2016, which in turnclaims priority to U.S. Provisional Patent Application Ser. No.62/190,627, entitled “Pressure Distributing Aligned Arrays of CushioningVoid Cells,” filed on Jul. 9, 2015, each of which are specificallyincorporated by reference for all they disclose.

BACKGROUND

Cushioning systems are used in a wide variety of applications includingcomfort and impact protection of the human body. A cushioning system isplaced adjacent a portion of the body and provides a barrier between thebody and one or more objects that would otherwise impinge on the body.For example, a pocketed spring mattress contains an array ofclose-coupled metal springs that cushion the body from a bed frame.Similarly, chairs, gloves, knee-pads, helmets, etc. may each include acushioning system that provides a barrier between a portion of the bodyand one or more objects.

A variety of structures are used for cushioning systems. For example, anarray of close-coupled, closed-cell air and/or water chambers oftenconstitutes air and water mattresses. An array of close-coupled springsoften constitutes a conventional mattress. Further examples includeopen- or closed-cell foam and elastomeric honeycomb structures.

For cushioning systems utilizing an array of closed or open cells orsprings, either the cells or springs are directly coupled together orone or more unifying layers are used to couple each of the cells orsprings together at their extremities. Directly coupling the cells orsprings together or indirectly coupling the extremities of the cells orsprings together is effective in tying the cushioning system together.

SUMMARY

Implementations described and claimed herein include a cellularcushioning system comprising a first matrix of void cells, and a secondmatrix of void cells opposing the first matrix of void cells, whereinone or more peaks of each void cell in the second matrix is attached toone or more peaks of each void cell in the first matrix, and wherein thevoid cells of the first matrix have a higher cell resolution than thevoid cells of the second matrix. In another implementation, a method ofmanufacturing a cushioning system includes molding a first matrix ofvoid cells, molding a second matrix of void cells, the void cells of thefirst matrix having a higher cell resolution than the void cells in thesecond matrix, and attaching peak surfaces of the void cells of thefirst matrix and peak surfaces of the void cells of the second matrixtogether. As a result, there is more even pressure distribution when acontoured object (e.g., a human body) is placed in contact with the topmatrix.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescriptions. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. These andvarious other features and advantages will be apparent from a reading ofthe following Detailed Descriptions.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1 illustrates a perspective top view of an example cellularcushioning system in an unloaded state.

FIG. 2 illustrates a perspective bottom view of an example cellularcushioning system.

FIG. 3 illustrates an elevation view of an example cellular cushioningsystem.

FIG. 4 illustrates a perspective bottom view of the example cellularcushioning system.

FIG. 5 illustrates an enlarged bottom view of the example cellularcushioning system of FIG. 4.

FIG. 6 illustrates a perspective bottom view of an example cellularcushioning system in an unloaded state.

FIG. 7 illustrates a perspective side view of an example cellularcushioning system in FIG. 6.

FIG. 8 illustrates a second side perspective view of an example cellularcushioning system in FIG. 6.

FIG. 9 illustrates an elevation view of an example cellular cushioning.

FIG. 10 illustrates a perspective view of an example cellular cushioningsystem.

FIG. 11 illustrates a top plan view of an example cellular cushioningsystem in an unloaded state.

FIG. 12 illustrates a bottom perspective view of an example wedgecellular cushioning system.

FIG. 13 illustrates a side perspective view of an example wedge cellularcushioning system.

FIG. 14 illustrates a top perspective view of an example wedge cellularcushioning system.

FIG. 15 illustrates an elevation view of an example wedge cellularcushioning system.

FIG. 16 illustrates a second elevation view of an example wedge cellularcushioning system.

FIG. 17 is a graph of example stress/strain curves of two cushioningsystems.

FIG. 18 is a flowchart of example operations for manufacturing anexample cushioning system.

DETAILED DESCRIPTIONS

FIG. 1 illustrates a perspective top view of an example cellularcushioning system 100 in an unloaded state. The cellular cushioningsystem 100 includes void cells (e.g., void cell 104 or void cell 107)arranged in two matrices. For purposes of this disclosure, the twomatrices are a top matrix 106 and a bottom matrix 108. However, inanother implementation, the top matrix and bottom matrix could bereferred to as right side and left side matrices, first and secondmatrices, bottom and top matrices, etc. depending on desired terminologyor configurations.

In FIG. 1, the top matrix 106 has void cells (e.g., void cell 104) thatare a substantially different size and/or shape than the void cells(e.g., void cell 107) in the bottom matrix 108. In one implementation,the void cells (e.g., void cell 107) in the bottom matrix 108 are largerand deeper than the void cells (e.g., void cell 104) in the top matrix106. In one implementation, the smaller void cells (e.g., void cell 104)are 54% smaller than the larger cells. In other implementations, thesmaller void cells (e.g., void cell 104) are 5-90% smaller than thelarger cells. The smaller void cells (e.g., void cell 104) in the topmatrix 106 have a higher cell resolution and lower depth than the largervoid cells (e.g., void cell 107) in the bottom matrix 108, yielding asofter, bottom matrix 108 and a more supportive and load-distributed,firm top matrix 106 for a user who may be sitting or walking on top ofthe matrices, for example.

The wall thickness of each of the void cells may vary over a height ofthe void cell. In each void cell, there is a peak or bottom surface,where the wall thickness may be thicker (or thinner) than the peaks orbottom surfaces of opposing void cells. The terminology for peak orbottom surface can vary depending on the implementation. In a void cellwhere the bottom surface is flat, the peak may be the entire bottomsurface. In an implementation where the bottom of the void cell is notflat and is shaped into a “peak” near the center of the bottom surface,then the peak is the tallest feature of the bottom surface. In animplementation where the bottom surface of a void cell 107 issubstantially flat, such as in FIG. 1, the wall thickness may be greaterthan the peak or bottom surface 116 of void cell 107, or vice versa.Varying the wall thickness of the void cells over their height can beused to yield a changing resistive force depending upon the amount ofcompression of the void cells (i.e., yielding a positive and/orincreasing spring rate). As a result, there is even more pressuredistribution across the top matrix 108 when a contoured object (e.g., ahuman body) is placed in contact with the top matrix 106.

The arrangement of void cells in the matrices can vary. In theimplementation in FIG. 1, the center of the smaller void cells (e.g.,void cell 104) in the top matrix 106 are aligned with the corners of thelarger opposing void cell (e.g., void cell 107) with a 4:1 ratio ofsmaller void cells in the top matrix to a larger void cell in the bottommatrix. In another implementation, there may be two void cells in a topmatrix opposing a void cell in a bottom matrix (e.g., a 2:1 ratio).Further, there can be other ratios of smaller void cells in the topmatrix to the larger void cells in the bottom matrix. In someimplementations, void cells in the bottom matrix 108 and the top matrix106 may be offset such that they are only partially opposing or notopposing.

In implementations where the void cells are partially opposing othervoid cells, as opposed to directly opposing each other, there is lessmaterial in the center of each opposing void cell. Particularly inimplementations where there are smaller void cells in a top matrix andlarger void cells in a bottom matrix, the edges of the smaller voidcells are layered on the edges of the larger void cells. Theseimplementations provide more flexibility, improved pressuredistribution, more comfort to a user, and/or more mitigating impact.

The different densities of void cells between top and bottom matricesresults in each lower density matrix cell (e.g., void cell 107) beingbonded to multiple higher density matrix cells (e.g., void cell 104),preventing the possibility of one void cell inverting over another voidcell as the geometries are mismatched. Having layers of different voiddensities allows for top and bottom matrices of different heights;allowing for the top and bottom matrices to have a different relativestiffness, though the top and bottom matrices materials can be modifiedto avoid this, if desired.

The cellular cushioning system 100 may be manufactured using a varietyof manufacturing processes (e.g., blow molding, thermoforming,extrusion, injection molding, laminating, etc.). In one implementation,the system 100 is manufactured by forming two separate matrices, a topmatrix 106 and a bottom matrix 108. The two matrices are then welded,laminated, glued, or otherwise attached together at the peaks or bottomsurfaces of the void cells in the top matrix 106 and the bottom matrix108. For example, the peaks of the void cells (e.g., peak 118) of thetop matrix 106 are attached to the peaks (e.g., peak 116) of the voidcells of the bottom matrix 108.

Due to varying configurations with a different number of void cells inthe two matrices, the attachment of the void cells to each other mayoccur at different points of contact on each void cell. For example,void cell 104, which is smaller than void cell 107, may attach to voidcell 107 with the majority of the peak surface of the void cell 104 andvoid cell 110 attaching to only the peak surface corners of the voidcell 107.

The void cells are hollow chambers that resist deflection due tocompressive forces, similar to compression springs. However, unlikecompression springs, deflection of the void cells does not yield alinear increase in resistive force. Instead, the resistive force todeflection of the void cells is relatively constant for the majority ofthe void cells' compression displacement. This allows the cellularcushioning system 100 to conform to a user's body with an even force onthe user's body. In other implementations, each of the void cells mayhave a positive or negative spring rate. Further, the spring rate ofeach of the void cells may vary depending upon the void cell's relativeposition within the cellular cushioning system 100.

At least the material, wall thickness, size, and shape of each of thevoid cells define the resistive force each of the void cells can apply.Materials used for the void cells are generally elastically deformableunder expected load conditions and will withstand numerous deformationswithout fracturing or suffering other breakdown impairing the functionof the cellular cushioning system 100. Example materials includethermoplastic urethane, thermoplastic elastomers, styrenic co-polymers,rubber, Dow Pellethane®, Lubrizol Estane®, Dupont™ Hytrel®, ATOFINAPebax®, and Krayton polymers. Further, the wall thickness may range from5 mil to 80 mil. Still further, the size of each of the void cells mayrange from 5 mm to 70 mm sides in a cubical implementation. Further yet,the void cells may be cubical, pyramidal, hemispherical, or any othershape capable of having a hollow interior volume. Other shapes may havesimilar dimensions as the aforementioned cubical implementation. Stillfurther, the void cells may be spaced a variety of distances from oneanother. An example spacing range is 2.5 mm to 150 mm.

In one implementation, the void cells have a square or rectangular baseshape, with a trapezoidal volume and a rounded top. That void cellgeometry may provide a smooth compression profile of the system 100 andminimal bunching of the individual void cells. Bunching occursparticularly on corners and vertical sidewalls of the void cells wherethe material buckles in such a way as to create multiple folds ofmaterial that can cause pressure points and a less uniform feel to thecellular cushioning system overall. Still further, rounded tops of thevoid cells may enhance user comfort and the spacing of the individualvoid cells may create a user feel similar to convoluted foam.

In another implementation, the void cells have a round base shape, witha cylindrical-shaped volume and a rounded top. That void cell geometrymay also provide a smooth compression profile of a cellular cushioningsystem and minimal bunching of the individual void cells. Still further,the rounded tops may enhance user comfort and the closer spacing of theindividual void cells may create a more uniform feel to a user. Othervoid cell shapes are contemplated herein.

The material, wall thickness, cell size, and/or cell spacing of thecells within the cellular cushioning system 100 may be optimized tominimize generation of mechanical noise by compression (e.g., bucklingof the side walls) of the void cells. For example, properties of thecells may be optimized to provide a smooth relationship betweendisplacement and an applied force. Further, a light lubricating coating(e.g., talcum powder or oil) may be used on the exterior of the voidcells to reduce or eliminate noise generated by void cells contactingand moving relative to one another. Reduction or elimination ofmechanical noise may make use of the cellular cushioning system 100 morepleasurable to the user. Still further, geometry of the top of the voidcells may be smooth to enhance user comfort.

Each void cell is surrounded by neighboring void cells within a matrix.For example, void cell 104 is surrounded by three neighboring void cells110 within the top matrix 106. In cellular cushioning system 100, thereare three neighboring void cells for each corner void cell, fiveneighboring void cells for each edge cell, and eight neighboring voidcells for the rest of the void cells. Other implementations may havegreater or fewer neighboring void cells for each void cell. Further,each void cell has one or more corresponding opposing void cell withinan opposite matrix. For example, void cell 104 in the top matrix 106 isopposed by void cell 107 in the bottom matrix.

The neighboring void cells, opposing void cells, and neighbor opposingvoid cells are collectively referred to herein as adjacent void cells.In various implementations, one or more of the neighboring void cells,opposing void cells, and opposing neighbor void cells are notsubstantially compressed within an independent compression range of anindividual void cell.

In one implementation, the void cells are filled with ambient air andopen to the atmosphere. In another implementation, the void cells arefilled with a foam or a fluid other than air. The foam or certain fluidsmay be used to insulate a user's body, facilitate heat transfer from theuser's body to/from the cellular cushioning system 100, and/or affectthe resistance to deflection of the cellular cushioning system 100. In avacuum or near-vacuum environment (e.g., outer space), the hollowchambers may be un-filled.

Further, the void cells may have one or more apertures or holes (notshown) through which air or other fluid may pass freely when the voidcells are compressed and de-compressed. By not relying on air pressurefor resistance to deflection, the void cells can achieve a relativelyconstant resistance force to deformation. Still further, the void cellsmay be open to one another (i.e., fluidly connected) via passages (notshown) through the matrix. The holes and/or passages may also be used tocirculate fluid for heating or cooling purposes. For example, the holesand/or passages may define a path through the cellular cushioning system100 in which a heating or cooling fluid enters the cellular cushioningsystem 100, follows a path through the cellular cushioning system 100,and exits the cellular cushioning system 100. The holes and/or passagesmay also control the rate at which air may enter, move within, and/orexit the cellular cushioning system 100. For example, for heavy loadsthat are applied quickly, the holes and/or passages may restrict howfast air may exit or move within the cellular cushioning system 100,thereby providing additional cushioning to the user.

The holes may be placed on mating surfaces of opposing void cells on thecellular cushioning system 100 to facilitate cleaning. Morespecifically, water and/or air could be forced through the holes in theopposing void cells to flush out contaminants. In an implementationwhere each of the void cells is connected via passages, water and/or aircould be introduced at one end of the cellular cushioning system 100 andflushed laterally through the cellular cushioning system 100 to theopposite end to flush out contaminants. Further, the cellular cushioningsystem 100 could be treated with an anti-microbial substance or thecellular cushioning system 100 material itself may be anti-microbial.

FIG. 2 illustrates a perspective bottom view of an example cellularcushioning system. The cellular cushioning system 200 includes voidcells (e.g., void cell 204 or void cell 207) arranged in a top matrix206 and a bottom matrix 208. The top matrix 206 has void cells (e.g.,void cell 204) that are a substantially different size and/or shape thanthe void cells in the bottom matrix 208. The smaller void cells in thetop matrix 206 have a higher cell resolution and lower depth than thelarger void cells in the bottom matrix 208, yielding a softer bottommatrix 208 and a more supportive and load-distributed, firm top matrix206. As a result, there is more even pressure distribution when acontoured object (e.g., a human body) is placed in contact with the topmatrix 206.

The smaller void cells (e.g., void cell 204) in the top matrix 206 arealigned with the corners of the larger opposing void cell (e.g., voidcell 207) in the bottom matrix 208. In this example, there is a 4:1ratio of smaller void cells in the top matrix 206 to the larger voidcells in the bottom matrix 208. In another implementation, there mayfour void cells in a bottom matrix 208 opposing a void cell in a topmatrix 206 (e.g., a 2:1 ratio). Further, there can be other ratios ofsmaller void cells 204 in the top matrix 206 to the larger void cells207 in the bottom matrix 208.

Void cells (e.g., void cell 204) which are smaller than void cell 207,attach to void cell 207 with the surfaces of their peaks to only thesurface corners of the larger void cell 207. The void cells in the topmatrix 206 align with the void cells in the bottom matrix 208 in a 4:1ratio with four void cells of the top matrix 206 molded to one void cellin the bottom matrix 208. The interface where the top matrix 206 ismolded to the bottom matrix 208 may be the surface of the peaks (notshown) of the void cells on the bottom matrix 208 to corners of thepeaks of the void cells in the top matrix 206. The location ofattachment can vary.

In FIG. 2, there are channels (e.g., channel 214) adjacent and inbetween the void cells (e.g., void cell 207) located on the perimeter ofthe cellular cushioning system 200. The channels 214 primarily functionto break up the surface of the interface providing a partiallyindependent compression of a localized region up to a point. Thechannels 214 can also be used to prevent the trapping of air betweencells. The channels 214 may also be built in for manufacturing purposesto promote more consistent forming. The channels may be of varying sizesand in some implementations, the channels 214 can have a depth thatseparates the void cells and defines inverted void cells (see FIG. 6).

FIG. 3 illustrates an elevation view of an example cellular cushioningsystem 300. The cellular cushioning system 300 includes void cells(e.g., void cell 304) arranged in a top matrix 306 and a bottom matrix308.

The top matrix 306 has void cells (e.g., void cell 304) that are asubstantially different size and/or shape than the void cells in thebottom matrix 308. Specifically, the void cells (e.g., void cell 307) inthe bottom matrix 308 are larger and deeper than the void cells (e.g.,void cell 304) in the top matrix 306. The smaller void cells in the topmatrix 306 have a higher cell resolution and lower depth than the largervoid cells in the bottom matrix 308, yielding a softer bottom matrix 308and a more supportive top matrix 306.

The interface where the top matrix 306 is attached to the bottom matrix308 may be the surface of the peaks (e.g., peak 318) of the void cellson the bottom matrix 308 to corners of the peaks (e.g., peak 316) of thevoid cells in the top matrix 306. The location of attachment can vary.The two matrices are welded, laminated, glued, or otherwise attachedtogether at the peaks of the void cells in the top matrix 306 and thebottom matrix 308.

FIG. 4 illustrates a perspective bottom view of the example offsetcellular cushioning system. The cellular cushioning system 400 includesvoid cells (e.g., void cell 407) arranged in a top matrix (not shown)and a bottom matrix 408. The top matrix has void cells that are asubstantially different size and/or shape than the void cells in thebottom matrix 508. In one implementation, the void cells (e.g., voidcell 407) in the bottom matrix 508 are larger and deeper than the voidcells in the top matrix. The smaller void cells in the top matrix have ahigher cell resolution and lower depth than the larger void cells in thebottom matrix 508, yielding a softer bottom matrix 508 and a moresupportive top matrix 506.

The void cells in the bottom matrix 508 are offset from those in the topmatrix such that each void cell in a matrix overlaps two or moreopposing void cells. The two matrices are welded, laminated, glued, orotherwise attached together at the peaks of the void cells in the topmatrix and the bottom matrix 508. For example, the peaks of the voidcells in the top matrix are attached to the peaks of the void cells inthe bottom matrix 508.

In FIG. 5, there are channels (e.g., channel 514) adjacent and inbetween the void cells (e.g., void cell 507) located on the perimeter ofthe cellular cushioning system 500. The channels 514 primarily functionto break up the surface of the interface providing a partiallyindependent compression of a localized region up to a point. Thechannels 514 can also be used to prevent the trapping of air betweencells. The channels 514 may also be built in for manufacturing purposesto promote more consistent forming. The channels 514 may be of varyingsizes and in some implementations, the channels 514 can have a depththat separates the void cells and defines inverted void cells (see FIG.6).

FIG. 5 illustrates an enlarged bottom view of an example cellularcushioning system of FIG. 4. The cellular cushioning system 500 includesvoid cells (e.g., void cell 504 or void cell 407) arranged in a topmatrix and a bottom matrix, which are shown but not distinguishedbecause of their transparency over each other. The top matrix has voidcells (e.g., void cell 404) that are a substantially different sizeand/or shape than the void cells in the bottom matrix (e.g., void cell407).

Specifically, the void cells in the bottom matrix (e.g., void cell 407)are larger and deeper than the void cells (e.g., void cell 404) in thetop matrix. The top matrix of void cells has a higher cell resolutionand lower depth than the bottom matrix, yielding a softer bottom matrixand a more supportive upper matrix 406. As a result, there is more evenpressure distribution across the upper matrix when a contoured object(e.g., a human body) is placed in contact with the top matrix.

The smaller void cells (e.g., void cell 404) in the top matrix arealigned with the corners of the larger opposing void cell (e.g., voidcell 407). In this example, there is a ratio of smaller void cells inthe top matrix to the larger void cells in the bottom matrix that vary.For example, in FIG. 4, a center void cell has a ratio of 2:1. Inanother implementation, there may be a 4:1 ratio or in anotherimplementation there may be more or less than four void cells in a topmatrix opposing a void cell in a bottom matrix (e.g., a 3:1 ratio).However, there can be other ratios of smaller void cells in the topmatrix to the larger void cells in the bottom matrix, and there can bediffering ratios of void cells within the same cellular cushioningsystem, (e.g., a 4:1 ratio for some opposing cells, and a 2:1 ratio forother opposing cells).

The void cell 404, which is smaller than void cell 407, attaches to voidcell 407 with the surface of its peak to only the surface corners of thelarger void cell 407. The void cells in the top matrix in thisimplementation align with the void cells in the bottom matrix in a 2:1ratio with two void cells of the top matrix molded to one void cell inthe bottom matrix. The interface where the top matrix is attached to thebottom matrix may be the surface of the peaks of the void cells on thetop matrix to corners of the peaks of the void cells in the bottommatrix. The location of attachment can vary.

In FIG. 4, there are channels (e.g., channel 414) adjacent and inbetween the void cells (e.g., void cell 407) located on the perimeter ofthe cellular cushioning system 400. The channels 414 primarily functionto break up the surface of the interface providing a partiallyindependent compression of a localized region up to a point. Thechannels 414 can also be used to prevent the trapping of air betweencells. The channels 414 may also be built in for manufacturing purposesto promote more consistent forming. The channels 414 may be of varyingsizes and in some implementations, the channels 414 can have a depththat separates the void cells and defines inverted void cells (see FIG.6).

FIG. 6 illustrates a perspective bottom view of an example cellularcushioning system 600 in an unloaded state. The cellular cushioningsystem 600 includes void cells (e.g., void cell 604 or void cell 607)arranged in two matrices. For purposes of this disclosure, the twomatrices are a top matrix 606 and a bottom matrix 608. However, inanother implementation, the top matrix and bottom matrix could bereferred to as right side and left side matrices, first and secondmatrices, bottom and top matrices, etc. depending on desired terminologyor configurations.

In FIG. 6, the top matrix 606 has void cells (e.g., void cell 604) thatare a substantially different size and/or shape than the void cells(e.g., void cell 607) in the bottom matrix 608. In one implementation,the void cells (e.g., void cell 607) in the bottom matrix 608 are largerand deeper than the void cells (e.g., void cell 604) in the top matrix606. The smaller void cells in the top matrix 606 have a higher cellresolution and lower depth than the larger void cells in the bottommatrix 608, yielding a softer bottom matrix 608 and a more supportivetop matrix 606.

The wall thickness of each of the void cells may vary over a height ofthe void cell. In each void cell, there is a peak or bottom surface,where the wall thickness may be thicker (or thinner) than the peaks orbottom surfaces of opposing void cells. The terminology for peak orbottom surface can vary depending on the implementation. In a void cellwhere the bottom surface is flat, the peak may be the entire bottomsurface. In an implementation where the bottom of the void cell is notflat and is shaped into a “peak” near the center of the bottom surface,then the peak is the tallest feature of the bottom surface. In animplementation where the bottom surface of a void cell 604 issubstantially flat, such as in FIG. 1, the wall thickness may be greaterthan the peak or bottom surface 616 of void cell 604, or vice versa.Varying the wall thickness of the void cells over their height can beused to yield a changing resistive force depending upon the amount ofcompression of the void cells (i.e., yielding a positive and/orincreasing spring rate). As a result, there is even more pressuredistribution across the top matrix 608 when a contoured object (e.g., ahuman body) is placed in contact with the top matrix 606.

The arrangement of void cells in the matrices can vary. In theimplementation in FIG. 6, the smaller void cells (e.g., void cells 604and 609) in the top matrix 606 are aligned with the corners of thelarger opposing void cell (e.g., void cell 607) with a 4:1 ratio ofsmaller void cells in the top matrix 606 to a larger void cell in thebottom matrix 608. In another implementation, there may be more or lessthan four void cells in a top matrix 606 opposing a void cell in abottom matrix 608 (e.g., a 2:1 ratio). However, there can be otherratios of smaller void cells in the top matrix 606 to the larger voidcells in the bottom matrix 608. In some implementations, void cells inthe top matrix 606 and the bottom matrix 608 may be offset such thatthey are only partially opposing or not opposing (see e.g., FIG. 9).

The cellular cushioning system 600 may be manufactured using a varietyof manufacturing processes (e.g., blow molding, welding, thermoforming,extrusion, injection molding, laminating, etc.). In one implementation,the system 600 is manufactured by forming two separate matrices, a topmatrix 606 and a bottom matrix 608. The two matrices are then welded,laminated, glued, or otherwise attached together at the peaks or bottomsurfaces of the void cells in the top matrix 606 and the bottom matrix608. For example, the peaks of the void cells (e.g., peak 616) of thetop matrix 606 are attached to the peaks (e.g., peak 618) of the voidcells of the bottom matrix 608.

Due to varying configurations with a different number of void cells inthe two matrices, the attachment of the void cells to each other mayoccur at different points of contact on each void cell. For example,void cells 604 and 609, which are smaller than void cell 607, may attachto void cell 607 with the majority of the peak surface of the void cells604 and 609 attaching to only the peak surface corners of the void cell607.

In some implementations, there may be channels between at least some ofthe void cells in a matrix. In FIG. 6, the bottom matrix 608 includessignificant channels (e.g., channels 614) that separate the void cells(e.g., void cells 607 and 610) in the top matrix 606 and the bottommatrix 608. In an implementation where there are channels between allthe void cells in the top matrix of a cushioning system, as shown inFIG. 6, the channels define inverted void cells (e.g., inverted voidcell 612) that are evenly distributed within the bottom matrix 608. InFIG. 6, there are four inverted void cells defined by the twelvechannels between nine void cells. However, the number of void cells andthe number of channels can vary depending on the implementation.

The void cells are hollow chambers that resist deflection due tocompressive forces, similar to compression springs. However, unlikecompression springs, deflection of the void cells does not yield alinear increase in resistive force. Instead, the resistive force todeflection of the void cells is relatively constant for the majority ofthe void cells' compression displacement. This allows the cellularcushioning system 600 to conform to a user's body with an even force onthe user's body. In other implementations, each of the void cells mayhave a positive or negative spring rate. Further, the spring rate ofeach of the void cells may vary depending upon the void cell's relativeposition within the cellular cushioning system 600.

At least the material, wall thickness, size, and shape of each of thevoid cells define the resistive force each of the void cells can apply.Materials used for the void cells are generally elastically deformableunder expected load conditions and will withstand numerous deformationswithout fracturing or suffering other breakdown impairing the functionof the cellular cushioning system 600. Example materials includethermoplastic urethane, thermoplastic elastomers, styrenic co-polymers,rubber, Dow Pellethane®, Lubrizol Estane®, Dupont™ Hytrel®, ATOFINAPebax®, and Krayton polymers. Further, the wall thickness may range from5 mil to 80 mil. Still further, the size of the sides of each of thevoid cells may range from 5 mm to 70 mm in a cubical implementation.Further yet, the void cells may be cubical, pyramidal, hemispherical, orany other shape capable of having a hollow interior volume. Other shapesmay have similar dimensions as the aforementioned cubicalimplementation. Still further, the void cells may be spaced a variety ofdistances from one another. An example spacing range is 2.5 mm to 150mm.

In one implementation, the void cells have a square or rectangular baseshape, with a trapezoidal volume and a rounded top. That void cellgeometry may provide a smooth compression profile of the system 600 andminimal bunching of the individual void cells. Bunching occursparticularly on corners and vertical sidewalls of the void cells wherethe material buckles in such a way as to create multiple folds ofmaterial that can cause pressure points and a less uniform feel to thecellular cushioning system overall. Still further, rounded tops of thevoid cells may enhance user comfort, and the spacing of the individualvoid cells may create a user feel similar to convoluted foam.

In another implementation, the void cells have a round base shape, witha cylindrical-shaped volume and a rounded top. That void cell geometrymay also provide a smooth compression profile of a cellular cushioningsystem and minimal bunching of the individual void cells. Still further,the rounded tops may enhance user comfort and the closer spacing of theindividual void cells may create a more uniform feel to a user. Othervoid cell shapes are contemplated herein.

The material, wall thickness, cell size, and/or cell spacing of thecells within the cellular cushioning system 600 may be optimized tominimize generation of mechanical noise by compression (e.g., bucklingof the side walls) of the void cells. For example, properties of thecells may be optimized to provide a smooth relationship betweendisplacement and an applied force. Further, a light lubricating coating(e.g., talcum powder or oil) may be used on the exterior of the voidcells to reduce or eliminate noise generated by void cells contactingand moving relative to one another. Reduction or elimination ofmechanical noise may make use of the cellular cushioning system 600 morepleasurable to the user. Still further, geometry of the top of the voidcells may be smooth to enhance user comfort.

Each void cell is surrounded by neighboring void cells within a matrix.For example, void cell 604 is surrounded by three neighboring void cells610 within the top matrix 606. In cellular cushioning system 600, thereare three neighboring void cells for each corner void cell, fiveneighboring void cells for each edge cell, and eight neighboring voidcells for the rest of the void cells. Other implementations may havegreater or fewer neighboring void cells for each void cell. Further,each void cell has one or more corresponding opposing void cell withinan opposite matrix. For example, void cell 604 in the top matrix 606 isopposed by void cell 607 in the bottom matrix 608. Other implementationsdo not include opposing void cells for some or all of the void cells.

The neighboring void cells, opposing void cells, and neighbor opposingvoid cells are collectively referred to herein as adjacent void cells.In various implementations, one or more of the neighboring void cells,opposing void cells, and opposing neighbor void cells are notsubstantially compressed within an independent compression range of anindividual void cell.

In one implementation, the void cells are filled with ambient air andopen to the atmosphere. In another implementation, the void cells arefilled with a foam or a fluid other than air. The foam or certain fluidsmay be used to insulate a user's body, facilitate heat transfer from theuser's body to/from the cellular cushioning system 600, and/or affectthe resistance to deflection of the cellular cushioning system 600. In avacuum or near-vacuum environment (e.g., outer space), the hollowchambers may be un-filled.

Further, the void cells may have one or more apertures or holes (notshown) through which air or other fluid may pass freely when the voidcells are compressed and de-compressed. By not relying on air pressurefor resistance to deflection, the void cells can achieve a relativelyconstant resistance force to deformation. Still further, the void cellsmay be open to one another (i.e., fluidly connected) via passages (notshown) through the matrix. The holes and/or passages may also be used tocirculate fluid for heating or cooling purposes. For example, the holesand/or passages may define a path through the cellular cushioning system600 in which a heating or cooling fluid enters the cellular cushioningsystem 600, follows a path through the cellular cushioning system 600,and exits the cellular cushioning system 600. The holes and/or passagesmay also control the rate at which air may enter, move within, and/orexit the cellular cushioning system 600. For example, for heavy loadsthat are applied quickly, the holes and/or passages may restrict howfast air may exit or move within the cellular cushioning system 600,thereby providing additional cushioning to the user.

The holes may be placed on mating surfaces of opposing void cells on thecellular cushioning system 600 to facilitate cleaning. Morespecifically, water and/or air could be forced through the holes in theopposing void cells to flush out contaminants. In an implementationwhere all of the void cells are connected via passages, water and/or aircould be introduced at one end of the cellular cushioning system 600 andflushed laterally through the cellular cushioning system 600 to theopposite end to flush out contaminants. Further, the cellular cushioningsystem 600 could be treated with an anti-microbial substance or thecellular cushioning system 600 material itself may be anti-microbial.

FIG. 7 illustrates a perspective side view of an example cellularcushioning system. The cellular cushioning system 700 includes voidcells (e.g., void cell 704 or void cell 707) arranged in a top matrix706 and a bottom matrix 708. The top matrix 706 has void cells (e.g.,void cell 704) that are a substantially different size and/or shape thanthe void cells in the bottom matrix 708. Specifically, the void cells(e.g., void cell 707) in the bottom matrix 708 are larger and deeperthan the void cells (e.g., void cell 704) in the top matrix 706. The topmatrix 706 of void cells has a higher cell resolution and lower depththan the bottom matrix 708, yielding a softer bottom matrix 708 and amore supportive top matrix 706. As a result, there is more even pressuredistribution across the top matrix 706 when a contoured object (e.g., ahuman body) is placed in contact with the top matrix 706.

The smaller void cells (e.g., 704, 709, and 711) in the bottom matrix708 are aligned with the corners of the larger opposing void cell (e.g.,707). In this example, there is a 4:1 ratio of smaller void cells in thetop matrix 706 to the larger void cells in the bottom matrix 708. Inanother implementation, there may be more or less than four void cellsin a top matrix 706 opposing a void cell in a bottom matrix 708 (e.g., a2:1 ratio). However, there can be other ratios of smaller void cells inthe top matrix 706 to the larger void cells in the bottom matrix 708.

Void cells 704 and 709, which are smaller than void cell 707, attach tovoid cell 707 with the surfaces of their peaks to only the surfacecorners of the larger void cell 707. The void cells in the top matrix706 align with the void cells in the bottom matrix 708 in the 4:1 ratiowith four void cells of the top matrix 706 molded to one void cell inthe bottom matrix 708. The interface where the top matrix 706 is moldedto the bottom matrix 708 may be the surface of the peaks (e.g., peak716) of the void cells on the bottom matrix 708 to corners of the peaks(e.g., peak 718) of the void cells in the top matrix 706. The locationof attachment can vary.

The bottom matrix 708 includes significant channels (e.g., channel 714)that separate the void cells (e.g., void cells 707 and 710) in thebottom matrix 708. The channels define inverted void cells (e.g.,inverted void cell 712) that are evenly distributed within the bottommatrix 708. In FIG. 7, there are four inverted void cells 712 defined bythe channels 714 between nine void cells. However, the number of voidcells and the number of channels can vary depending on theimplementation.

FIG. 8 illustrates a second side perspective view of an example cellularcushioning system. The cellular cushioning system 800 includes voidcells (e.g., void cell 804 or void cell 807) arranged in a top matrix806 and a bottom matrix 808. The top matrix 806 has void cells (e.g.,void cell 804) that are a substantially different size and/or shape thanthe void cells in the bottom matrix 808. Specifically, the void cells(e.g., void cell 807) in the bottom matrix 808 are larger and deeperthan the void cells (e.g., void cell 804) in the top matrix 806. The topmatrix 806 of void cells has a higher cell resolution and lower depththan the bottom matrix 808, yielding a softer bottom matrix 808 and amore supportive top matrix 806. As a result, there is more even pressuredistribution across the top matrix 806 when a contoured object (e.g., ahuman body) is placed in contact with the top matrix 806.

The smaller void cells (e.g., 807, 809, 811, and 818) in the bottommatrix 808 are aligned with the corners of the larger opposing void cell(e.g., void cell 804). In this example, there is a 4:1 ratio of smallervoid cells in the top matrix 806 to the larger void cells in the bottommatrix 808. In another implementation, there may be more or less thanfour void cells in a bottom matrix opposing a void cell in a top matrix806 (e.g., a 2:1 ratio). However, there can be other ratios of smallervoid cells in the top matrix 806 to the larger void cells in the bottommatrix 808.

Void cells 807 and 809, which are smaller than void cell 804, attach tovoid cell 804 with the surfaces of their peaks to only the surfacecorners of the larger void cell 804. The void cells in the top matrix806 align with the void cells in the bottom matrix 808 in the 4:1 ratiowith four void cells of the bottom matrix 808 molded to one void cell inthe top matrix 806. The interface where the top matrix 806 is attachedto the bottom matrix 808 may be the surface of the peaks (e.g., peak816) of the void cells on the bottom matrix 808 to corners of the peaks(e.g., peak 818) of the void cells in the top matrix 806. The locationof attachment can vary.

The top matrix 806 includes significant channels (e.g., channels 814)that separate the void cells in the top matrix 806. The channels defineinverted void cells (not shown) that are evenly distributed within thetop matrix 806. In FIG. 8, there are four inverted void cells (notshown) defined by the channels 814 between nine void cells. However, thenumber of void cells and the number of channels can vary depending onthe implementation.

FIG. 9 illustrates an elevation view of an example cellular cushioningsystem 900. The cellular cushioning system 900 includes void cells(e.g., void cell 904) arranged in a top matrix 906 and a bottom matrix908.

The top matrix 906 has void cells (e.g., void cell 904) that are asubstantially different size and/or shape than the void cells (e.g.,void cell 907) in the bottom matrix 908. Specifically, the void cells(e.g., void cell 907) in the bottom matrix 908 are larger and deeperthan the void cells (e.g., void cell 904) in the top matrix 906. Thesmaller void cells in the top matrix 906 have a higher cell resolutionand lower depth than the larger void cells in the bottom matrix 908,yielding a softer bottom matrix 908 and a more supportive top matrix906.

The interface where the top matrix 906 is attached to the bottom matrix908 may be the surface of the peaks (e.g., peak 918) of the void cellson the bottom matrix 908 to corners of the peaks (e.g., peak 916) of thevoid cells in the top matrix 906. The location of attachment can vary.The two matrices are welded, laminated, glued, or otherwise attachedtogether at the peaks of the void cells in the top matrix 906 and thebottom matrix 908. For example, the peaks of the void cells (e.g., peak916) of the top matrix 906 are attached to the peaks (e.g., peak 918) ofthe void cells of the bottom matrix 908.

FIG. 10 illustrates a perspective view of an example offset cellularcushioning system. The cellular cushioning system 1000 includes voidcells (e.g., void cell 1004) arranged in a top matrix 1006 and a bottommatrix 1008. The top matrix 1006 has void cells (e.g., void cell 1004)that are a substantially different size and/or shape than the void cellsin the bottom matrix 1008. In one implementation, the void cells (e.g.,void cell 1007) in the bottom matrix 1008 are larger and deeper than thevoid cells (e.g., void cell 1004) in the top matrix 1006. The smallervoid cells in the top matrix 1006 have a higher cell resolution andlower depth than the larger void cells in the bottom matrix 1008,yielding a softer bottom matrix 1008 and a more supportive top matrix1006.

The void cells in the top matrix 1006 are offset from those in thebottom matrix 1008 such that each void cell in a matrix overlaps two ormore opposing void cells. The two matrices are welded, laminated, glued,or otherwise attached together at the peaks of the void cells in the topmatrix 1006 and the bottom matrix 1008. For example, the peaks of thevoid cells (e.g., peak 1016) of the top matrix 1006 are attached to thepeaks (e.g., peak 1018) of the void cells of the bottom matrix 1008.

FIG. 11 illustrates a top plan view of an example cellular cushioningsystem 1100. The cellular cushioning system 1100 includes void cells(e.g., void cell 1104) arranged in the top matrix 1106. The two matricesare welded, laminated, glued, or otherwise attached together at thepeaks of the void cells in the top matrix 1106 and the bottom matrix1108. For example, the peaks of the void cells (e.g., peak 1116) of thetop matrix 1106 are attached to the peaks (e.g., peak 1118) of the voidcells of the bottom matrix 1108.

In FIG. 11, there are channels (e.g., channel 1114) adjacent and inbetween the void cells (e.g., void cell 1106) located on the perimeterof the cellular cushioning system 1100. The channels 1114 primarilyfunction to break up the surface of the interface providing a partiallyindependent compression of a localized region up to a point. Thechannels 1114 can also be used to prevent the trapping of air betweencells. The channels 1114 may also be built in for manufacturing purposesto promote more consistent forming. The channels 1114 may be of varyingsizes and in some implementations, the channels 1114 can have a depththat separates the void cells and defines inverted void cells (see FIG.12).

FIG. 12 illustrates a perspective bottom view of an example wedgecellular cushioning system 1200 in an unloaded state. The cellularcushioning system 1200 includes void cells (e.g., void cell 1204)arranged in a top matrix 1206 and a bottom matrix 1208. The top matrix1206 has void cells (e.g., void cell 1204) that are a substantiallydifferent size and/or shape than the void cells in the bottom matrix1208. Specifically, the void cells (e.g., void cell 1207) in the bottommatrix 1208 are larger and deeper than the void cells (e.g., void cell1204) in the top matrix 1206. The smaller void cells in the top matrix1206 have a higher cell resolution and lower depth than the larger voidcells in the bottom matrix 1208, yielding a softer bottom matrix 1208and a more supportive top matrix 1206. The peak surface of the voidcells of the top matrix 1206 is attached to the peak surface of the voidcells of the bottom matrix 1208.

The bottom matrix 1208 includes significant channels (e.g., channel1214) that separate the void cells in the bottom matrix 1208. Thechannels 1214 define inverted void cells (e.g., inverted void cell 1212)that are evenly distributed within the top matrix.

The wedge shape of the cushioning system is intended to accommodatecertain sized spaces. For example, if the wedge cellular cushioningsystem is intended for use in a bucket seat of a vehicle, a wedge shapemay be required to spatially or directionally fit the cushioning systemin a predetermined sized bucket.

As shown in FIG. 12, the wedge cellular cushioning system 1200 iswedge-shaped with the end 1236 of the wedge cellular cushioning systemhaving a greater height than the end 1230 of the wedge due to thedifference in height/depth of the void cells in the wedge cellularcushioning system 1200 decreasing from one end to another end. At theend 1230, the matrices 1206 and 1208 are compressed substantially flatagainst each other.

FIG. 13 illustrates a side perspective view of an example wedge cellularcushioning system 1300. The cellular cushioning system 1300 includesvoid cells (e.g., void cell 1304) arranged in a top matrix 1306 and abottom matrix 1308. The top matrix 1306 has void cells (e.g., void cell1304) that are a substantially different size and/or shape than the voidcells in the bottom matrix 1308 (e.g., void cell 1307). Specifically,the void cells (e.g., void cell 1307) in the bottom matrix 1308 arelarger and deeper than the void cells (e.g., void cell 1304) in the topmatrix 1306. The smaller void cells in the top matrix 1306 have a highercell resolution and lower depth than the larger void cells in the bottommatrix 1308, yielding a softer bottom matrix 1308 and a more supportivetop matrix 1306.

The two matrices are welded, laminated, glued, or otherwise attachedtogether at the peaks of the void cells in the top matrix 1306 and thebottom matrix 1308. For example, the peaks of the void cells (e.g., peak1316) of the top matrix 1306 are attached to the peaks (e.g., peak 1318)of the void cells of the bottom matrix 1308.

The arrangement of void cells in the matrices can vary. In theimplementation in FIG. 13, the smaller void cells (e.g., void cells 1304and 1311 shown in FIG. 13) in the top matrix 1306 are aligned byattaching to one larger opposing void cell, with a 2:1 ratio of smallervoid cells in the top matrix 1306 to a larger void cell in the bottommatrix 1308. In another implementation, there may be more or less thantwo void cells in a top matrix 1306 opposing a void cell in a bottommatrix 1308 (e.g., a 1:1 ratio). However, there can be other ratios ofsmaller void cells in the top matrix 1306 to the larger void cells inthe bottom matrix 1308. In some implementations, void cells in the topmatrix 1306 and the bottom matrix 1308 may be offset such that they areonly partially opposing or not opposing (see e.g., FIG. 14).

In FIG. 13, there are channels (e.g., channel 1314) adjacent and inbetween the void cells (e.g., void cell 1306) located on the perimeterof the cellular cushioning system 1300. The channels 1314 primarilyfunction to break up the surface of the interface providing a partiallyindependent compression of a localized region up to a point. Thechannels 1314 can also be used to prevent the trapping of air betweencells. The channels 1314 may also be built in for manufacturing purposesto promote more consistent forming. The channels may be of varying sizesand in some implementations, the channels 1314 can have a depth thatseparates the void cells and defines inverted void cells (see FIG. 12).

FIG. 14 illustrates a top perspective view of an example wedge cellularcushioning system. The wedge cellular cushioning system 1400 includesvoid cells (e.g., void cell 1404, 1411) arranged in a top matrix 1406.The peak surfaces of the void cells in the top matrix 1406 are attachedto peak surfaces of the void cells in the bottom matrix (not shown). Thevoid cells in the top matrix 1406 have varying widths.

The wedge cellular cushioning system 1400 is wedge-shaped, where the topmatrix 1406 and the bottom matrix are compressed substantially flatagainst each other at end 1430 of the wedge cellular cushioning system,due to the difference in height/depth of the void cells in the wedgecellular cushioning system 1400 decreasing from one end to another end.

FIG. 15 illustrates an elevation view of the example wedge cellularcushioning system. The cellular cushioning system 1500 includes voidcells arranged in a top matrix 1506 and a bottom matrix 1508. The topmatrix 1506 has void cells (e.g., void cell 1504) that are asubstantially different size and/or shape than the void cells in thebottom matrix 1508. Specifically, the void cells (e.g., void cell 1507)in the bottom matrix 1508 are larger and deeper than the void cells(e.g., void cell 1504) in the top matrix 1506. The smaller void cells inthe top matrix 1506 have a higher cell resolution and lower depth thanthe larger void cells in the bottom matrix 1508, yielding a softerbottom matrix 1508 and a more supportive top matrix 1506.

The peak surfaces of the void cells in the top matrix 1506 are attachedto the peak surfaces of the void cells of the bottom matrix 1508. Thewedge cellular cushioning system 1500 is wedge-shaped, where thematrices 1506 and 1508 are compressed substantially flat against eachother at end 1530 of the wedge cellular cushioning system 1500, due tothe difference in height/depth of the void cells in the wedge cellularcushioning system 1500 decreasing from one end to another end.

FIG. 16 illustrates a second elevation view of the example wedgecellular cushioning system. The wedge cellular cushioning system 1600includes void cells (e.g., void cell 1604) arranged in a top matrix 1606and a bottom matrix 1608. The top matrix 1606 has void cells (e.g., voidcell 1604) that are a substantially different size and/or shape than thevoid cells in the bottom matrix 1608. Specifically, the void cells(e.g., void cell 1607) in the bottom matrix 1608 are larger and deeperthan the void cells (e.g., void cell 1604) in the top matrix 1606. Thesmaller void cells in the top matrix 1606 have a higher cell resolutionand lower depth than the larger void cells in the bottom matrix 1608,yielding a softer bottom matrix 1608 and a more supportive top matrix1606.

The top matrix includes significant channels (e.g., channel 1614) thatseparate the void cells in the bottom matrix 1608. The channels defineinverted void cells that are evenly distributed within the bottom matrix1608.

The peak surfaces of the void cells of the top matrix 1606 are attachedto the peak surfaces of the void cells of the bottom matrix 1608. Thesmaller void cells (e.g., void cells 1604 and 1611) in the top matrix1606 are aligned with the corners of the larger opposing void cells(e.g., void cells 1607) of the bottom matrix 1608.

FIG. 17 is a graph 1700 illustrating a comparison of the stress/straincurves for an example twin square cushioning system (depicted asopposing cell void cells in a solid line) and the disclosed cushioningsystem of different density void cell squares (4:1) (depicted asdifferential cell resolution void cells in a dotted line) of the samematerial. The graph shows the stress curves as a measurement of stress(Ibf/in²) vs. strain (in/in).

The stress/strain curves can change by modifying any number ofvariables. The graph shows the 4:1 twin square cushioning system has asmoother stress curve without discrete compression events (i.e., thesudden increase in spring rate of the twin square seen around 0.45strain) or sudden buckling (and negative spring rate) as compared to thetwin square cushioning system.

Measurements of the different densities of the void cells and relationto pressure distribution are shown in the difference in the perimetersof the void cells. The perimeter, or sidewall, of each void cellsupports the load. Therefore, the greater the total perimeter length ofvoid cells over a given area, the greater pressure distribution overthat given area will be. There is no absolute ratio, as the geometriesare adjustable, but the comparison between the twin square cushioningsystem example and the 4:1 cushioning system shows the higher densitylayer of the 4:1 squares has approximately 40% more perimeter length ofvoid cells over a given area.

FIG. 18 illustrates example operations 1800 for manufacturing and usinga cellular cushioning system. The cellular cushioning system may bemolded, or in other implementations manufactured using a variety ofmanufacturing processes (e.g., blow molding, thermoforming, extrusion,injection molding, laminating, etc.).

A first molding operation 1802 molds a top matrix of void cells. Asecond molding operation 1804 molds a bottom matrix of void cells. Thetop matrix has void cells that are a substantially different size and/orshape than the void cells in the bottom matrix (discussed in furtherdetail in operation 1804). In one implementation, the void cells in thebottom matrix are larger and deeper than the void cells in the topmatrix. The smaller void cells in the top matrix have a higher cellresolution and lower depth than the larger void cells in the bottommatrix, yielding a softer bottom matrix and a more supportive topmatrix.

The wall thickness of each of the void cells may vary over a height ofthe void cell. Varying the wall thickness of the void cells over theirheight can be used to yield a changing resistive force depending uponthe amount of compression of the void cells (i.e., yielding a positiveand/or increasing spring rate). As a result, there is more even pressuredistribution across the top matrix when a contoured object (e.g., ahuman body) is placed in contact with the top matrix.

The arrangement of void cells in the matrices can vary. There may bemore or less than four void cells in a top matrix opposing a void cellin a bottom matrix (e.g., a 4:1 ratio or a 2:1 ratio). There can beother ratios of smaller void cells in the top matrix to the larger voidcells in the bottom matrix. In some implementations, void cells in thetop matrix and the bottom matrix may be offset such that they are onlypartially opposing or not opposing.

The top matrix molded in operation 1802 and the bottom matrix molded inoperation 1804 can include significant channels that separate the voidcells in each matrix. In an implementation where there are channelsbetween all the void cells in the matrix of a cushioning system, thechannels define inverted void cells that are evenly distributed withinthe matrix. The number of void cells and the number of channels can varydepending on the implementation.

The void cells are hollow chambers that resist deflection due tocompressive forces, similar to compression springs. However, unlikecompression springs, deflection of the void cells does not yield alinear increase in resistive force. Instead, the resistive force todeflection of the void cells is relatively constant for the majority ofthe void cells' compression displacement. This allows the cellularcushioning system to conform to a user's body with an even force on theuser's body. In other implementations, each of the void cells may have apositive or negative spring rate. Further, the spring rate of each ofthe void cells may vary depending upon the void cell's relative positionwithin the cellular cushioning system.

At least the material, wall thickness, size, and shape of each of thevoid cells define the resistive force each of the void cells can apply.Materials used for the void cells are generally elastically deformableunder expected load conditions and will withstand numerous deformationswithout fracturing or suffering other breakdown impairing the functionof the cellular cushioning system. Example materials includethermoplastic urethane, thermoplastic elastomers, styrenic co-polymers,rubber, Dow Pellethane®, Lubrizol Estane®, Dupont™ Hytrel®, ATOFINAPebax®, and Krayton polymers. Further, the wall thickness may range from5 mil to 80 mil. Still further, the size of the sides of each of thevoid cells may range from 5 mm to 70 mm in a cubical implementation.Further yet, the void cells may be cubical, pyramidal, hemispherical, orany other shape capable of having a hollow interior volume. Other shapesmay have similar dimensions as the aforementioned cubicalimplementation. Still further, the void cells may be spaced a variety ofdistances from one another. An example spacing range is 2.5 mm to 150mm.

In one implementation, the void cells have a square or rectangular baseshape, with a trapezoidal volume and a rounded top. That void cellgeometry may provide a smooth compression profile of the system andminimal bunching of the individual void cells. Bunching occursparticularly on corners and vertical sidewalls of the void cells wherethe material buckles in such a way as to create multiple folds ofmaterial that can cause pressure points and a less uniform feel to thecellular cushioning system overall. Still further, rounded tops of thevoid cells may enhance user comfort and the spacing of the individualvoid cells may create a user feel similar to convoluted foam.

In another implementation, the void cells have a round base shape, witha cylindrical-shaped volume and a rounded top. That void cell geometrymay also provide a smooth compression profile of a cellular cushioningsystem and minimal bunching of the individual void cells. Still further,the rounded tops may enhance user comfort and the closer spacing of theindividual void cells may create a more uniform feel to a user. Othervoid cell shapes are contemplated herein.

An attaching operation 1806 attaches the top matrix of void cells andthe bottom matrix of void cells together. The two matrices can bewelded, laminated, glued, or otherwise attached together at the peaks ofthe void cells in the top matrix and the bottom matrix.

Due to varying configurations with a different number of void cells inthe two matrices, the attachment of the void cells to each other mayoccur at different points of contact on each void cell.

Each void cell is surrounded by neighboring void cells within a matrix.For example, each void cell is surrounded by three neighboring voidcells within the top matrix. In the cellular cushioning system, thereare three neighboring void cells for each corner void cell, fiveneighboring void cells for each edge cell, and eight neighboring voidcells for the rest of the void cells. Other implementations may havegreater or fewer neighboring void cells for each void cell. Further,each void cell has one or more corresponding opposing void cell withinan opposite matrix. For example, each void cell in the top matrix isopposed by a void cell in the bottom matrix. Other implementations donot include opposing void cells for some or all of the void cells.

The neighboring void cells, opposing void cells, and neighbor opposingvoid cells are collectively referred to herein as adjacent void cells.In various implementations, one or more of the neighboring void cells,opposing void cells, and opposing neighbor void cells are notsubstantially compressed within an independent compression range of anindividual void cell.

The above specification, examples, and data provide a completedescription of the structure and use of exemplary embodiments of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended. Furthermore, structuralfeatures of the different embodiments may be combined in yet otherembodiments without departing from the recited claims.

What is claimed is:
 1. A cellular cushioning system comprising: a firstmatrix of void cells; and a second matrix of void cells opposing thefirst matrix of void cells, wherein peaks of individual void cells ofthe first matrix are attached to opposing void cells of the secondmatrix, and wherein the first matrix of void cells has a higher cellresolution than the second matrix of void cells, wherein the void cellsof one or both of the first matrix and the second matrix each includeone or more holes through which fluid passes when the void cells arecompressed and de-compressed.
 2. The cellular cushioning system of claim1, wherein the void cells of the first matrix have a lower depth thanthe void cells of the second matrix.
 3. The cellular cushioning systemof claim 1, wherein at least two void cells of the first matrixpartially oppose one void cell of the second matrix.
 4. The cellularcushioning system of claim 1, further comprising: one or more channelsthat separate the void cells of at least one of the first matrix and thesecond matrix.
 5. The cellular cushioning system of claim 1, wherein theholes control a rate at which air enters and exits the cellularcushioning system.
 6. The cellular cushioning system of claim 1, whereinthe void cells of the first matrix and the void cells of the secondmatrix are molded by one of a thermoforming, extrusion, laminating, blowmolding, and injection molding process.
 7. The cellular cushioningsystem of claim 1, wherein the void cells of the first matrix and thesecond matrix are made of at least one of thermoplastic urethane,thermoplastic elastomers, styrenic co-polymers, and rubber.
 8. Thecellular cushioning system of claim 1, wherein the cellular cushioningsystem has a shape and size to fit within a predetermined space.
 9. Acellular cushioning system comprising: a first matrix of void cells; anda second matrix of void cells opposing the first matrix of void cells,wherein individual void cells of the first matrix are smaller thanindividual void cells of the second matrix, wherein the second matrix ofvoid cells is attached to the first matrix of void cells, wherein thefirst matrix of void cells has a higher cell resolution than the secondmatrix of void cells, and wherein multiple void cells of the firstmatrix oppose one larger void cell of the second matrix, wherein thevoid cells of one or both of the first matrix and the second matrix eachinclude one or more holes through which fluid passes when the void cellsare compressed and de-compressed.
 10. The cellular cushioning system ofclaim 9, wherein the void cells of the first matrix have a lower depththan the void cells of the second matrix.
 11. The cellular cushioningsystem of claim 9, further comprising: one or more channels thatseparate the void cells in at least one of the first matrix and thesecond matrix.
 12. The cellular cushioning system of claim 9, whereinthe cellular cushioning system has a shape and size to fit within apredetermined space.
 13. The cellular cushioning system of claim 9,wherein the holes control a rate at which air enters and exits thecellular cushioning system.
 14. A method of manufacturing a cellularcushioning system comprising: molding a first matrix of void cells;molding a second matrix of void cells, the first matrix of void cellshaving a higher cell resolution than the second matrix of void cells,wherein the void cells of one or both of the first matrix and the secondmatrix each include one or more holes through which fluid passes whenthe void cells are compressed and de-compressed; and welding peaksurfaces of void cells of the first matrix to peak surfaces of voidcells of the second matrix.
 15. The method of claim 14, wherein the voidcells of the first matrix have a lower depth than the void cells of thesecond matrix.
 16. The method of claim 14, wherein the cellularcushioning system has a shape and size to fit within a predeterminedspace.
 17. The method of claim 14, wherein welding the peak surfaces ofthe void cells of the first matrix to the peak surfaces of the voidcells of the second matrix includes at least two void cells in the firstmatrix opposing one void cell in the second matrix.
 18. The method ofclaim 14, wherein the holes control a rate at which air enters and exitsthe cellular cushioning system.
 19. The method of claim 14, whereinchannels between individual void cells are molded in at least one of thefirst matrix and the second matrix.
 20. The method of claim 14, whereinwelding the peak surfaces of the void cells of the first matrix to thepeak surfaces of the void cells of the second matrix forms awedge-shaped configuration of the cellular cushioning system.